Electrical contact enhancing coating

ABSTRACT

The electrical contact enhancing coating is a composition that includes finely divided precious metal particles mixed with a dielectric carrier to form a coating. The dielectric carrier is a vegetable oil (preferably soybean-based) carrier of the type used as a dielectric coolant in power transformers, and is preferably high in antioxidant content. In a first embodiment, the precious metal is 100% silver having an average particle size of about 5-10 μm. In a second embodiment, the precious metal is about 65-85% silver and 15-35% gold (average particle size 0.5-1.8 μm), by weight. In a third embodiment, the precious metal is about 65-85% silver, 12.5-30% gold, and 2.5-5% palladium (average particle size 0.5-1.8 μm), by weight. The precious metals may be cryogenically treated prior to mixing with the dielectric carrier.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to electrical contacts and connectors, andto compositions to improve electrical conductivity, and moreparticularly to an electrical contact enhancing coating for enhancingconductivity between electrical conductors.

2. Description of the Related Art

Electrical contacts and connectors are subject to oxidation fromexposure to the air and to damp, humid, or moist environments. Theoxides of many metals, e.g., copper oxides, are nonconductive, therebyincreasing electrical resistance, resulting in a loss of energy andpower transfer. In addition, when viewed under a microscope, machined orplated electrical contacts have a rough surface finish, sometimesresulting in less than 5% surface contact between the two conductors.The decreased surface contact between the two surfaces can result inmicro-arcing, with consequent distortion of audio and video signals,decreased power transfer, and lower energy efficiency.

Consequently, there is a need for a way to increase conductivity betweenelectrical connectors and contacts to increase energy efficiency anddecrease distortion of electrical signals. Thus, an electrical contactenhancing coating solving the aforementioned problems is desired.

SUMMARY OF THE INVENTION

The electrical contact enhancing coating is a composition that includesa finely divided precious metal powder component mixed with a dielectriccarrier component to form a coating. The dielectric carrier component isa vegetable oil (preferably soybean-based) carrier of the type used as adielectric coolant in power transformers, and is preferably high inantioxidant content. In a first embodiment, the precious metal is 100%silver having an average particle size of about 5-10 μm, the actualparticle size ranging up to 25 μm. In a second embodiment, the preciousmetal is about 65-85% silver and 15-35% gold (average particle size0.2-3 μm, actual particle size ranging up to 15 μm), by weight. In athird embodiment, the precious metal is about 65-85% silver, 12.5-30%gold, and 2.5-5% palladium (average particle size 0.5-1.8 μm, actualparticle size ranging up to 10 μm), by weight. The precious metals maybe cryogenically treated, preferably doubly, prior to mixing with thedielectric carrier.

The composition has the consistency of a thick paint. The composition isapplied to one side of the electrical connections while wet. Theelectrical connections are put together while the coating is still wet.The coating cures or hardens by polymerization of the dielectric carrierupon exposure to air over a period of time. The cured or hardeneddielectric protects the electrical connection from deterioration causedby oxidation, providing an electrical connection protectant that resultsin energy savings and extends the life of electrical connectors andcontacts. It is also believed that the precious metal particles areconditioned by the application of current and curing of the dielectricto provide an improved conductive path through the two electricalcontact surfaces, with better power transfer and fidelity of electrical(e.g., audio and visual) signal transfer.

These and other features of the present invention will become readilyapparent upon further review of the following specification.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is an electrical contact enhancing coating in theform of a composition that includes a finely divided precious metalpowder component mixed with a dielectric carrier component to form acoating. The composition has the consistency of a thick paint. Thecomposition is applied to one side of the electrical connections whilewet. The electrical connections are put together while the coating isstill wet. The coating cures or hardens by polymerization of thedielectric carrier upon exposure to air over a period of time, joiningthe two electrical components. The cured or hardened dielectric protectsthe electrical connection from deterioration caused by oxidation,providing an electrical connection protectant that results in energysavings and extends the life of electrical connectors and contacts. Itis also believed that the precious metal particles are conditioned bythe application of current and curing of the dielectric to provide animproved conductive path through the two electrical contact surfaces,with better power transfer and fidelity of electrical (e.g., audio andvisual) signal transfer. The two electrical components may later beseparated by using alcohol and a swab, since the dielectric carrier issoluble in alcohol.

The dielectric carrier is a vegetable oil (preferably soybean-based)carrier of the type used as a dielectric coolant in power transformers,and is preferably high in antioxidant content. Vegetable oil-baseddielectric fluids are well known in the electrical arts, and have gainedpopularity as a dielectric coolant in power transformers as analternative to mineral oil because of their higher flash point andresistance to fire, as well as biodegradability. It is preferred thatthe dielectric carrier be soybean-based, and also have a highantioxidant content either naturally or by admixture of organicantioxidant additives with the soybean oil. A representative dielectriccarrier suitable for use in the present invention is Envirotemp® FR3™Fluid (Envirotemp and FR3 are trademarks of Cooper Power Systems, Inc.of Houston, Tex.). Envirotemp FR3 contains greater than 98.5% naturalesters derived from edible seed oils, including saturated andunsaturated fatty acids with C₁₄ to C₂₂ chains, and less than 1.5%food-grade antioxidant additives to prevent the unsaturated bonds frompolymerizing with oxygen from the air.

In order to achieve the proper consistency of the coating, it has beenfound that the ratio of precious metal component to dielectric carriercomponent should range between about 65%-85% precious metal to about15%-35% dielectric carrier, by weight. A representative example wouldinclude 10 grams of precious metal component and 3.5 grams of dielectriccarrier component, a ratio of 74%:26% by weight.

In a first embodiment, the precious metal is 100% silver. The silver ispreferably of the flake form, and has an average particle size of about5-10 μm, the actual particle size ranging up to 25 μm. The silver may besubject to cryogenic treatment, preferably double cryogenic treatment,prior to mixing with the dielectric carrier, i.e., the silver flakes arelowered to the temperature of liquid nitrogen (about −320° C.) in rampedstages, then allowed to return to room temperature. This procedure maybe repeated twice. It is believed that cryogenic treatment rearrangesthe structure of the metal in such a manner that audiophiles find abetter reproduction of audio signals, e.g., better dynamic range,softened highs, etc.

In a second embodiment, the precious metal comprises a mixture ofbetween about 65%-85% silver and 15%-35% gold, by weight, morepreferably about 85% silver and 15% gold. The silver powder is a highlyconductive flake form with an average particle size of 5-10 μm, actualparticle size ranging up to 25 μm. The gold powder is a highlyconductive flake form with an average particle size of 0.2-3 μm, actualparticle size ranging up to 15 μm. The two precious metals are blendedtogether in the appropriate weight ratio, and may be subjected tocryogenic treatment, preferably double cryogenic treatment, as describedabove, prior to mixture with the dielectric carrier.

In a third embodiment, the precious metal comprises a mixture of betweenabout 65%-85% silver, about 12.5%-30% gold, and about 2.5%-5% palladium,by weight, more preferably about 85% silver, 12.5% gold and 2.5%palladium. The silver powder is a highly conductive flake form with anaverage particle size of 5-10 μm, actual particle size ranging up to 25μm. The gold powder is a highly conductive flake form with an averageparticle size of 0.2-3 μm, actual particle size ranging up to 15 μm. Thepalladium powder is a spherical-shaped material having an averageparticle size of about 0.5-1.8 μm, actual particle size ranging up to 10μm. The three precious metals are blended together in the appropriateweight ratio, and may be subjected to cryogenic treatment, preferablydouble cryogenic treatment, as described above, prior to mixture withthe dielectric carrier.

As noted above, the coating cures or hardens by polymerization of thedielectric carrier upon exposure to air over a period of time.Preliminary testing has shown that resistance across the electricalconnection is reduced by about 10% after a period of about four hours.However, the curing process may take considerable time, and a gradualenergy savings and increase of audio and visual signal transfer qualitywill be noted, with a leveling off after about three-eight monthscuring.

It is believed that the precious metal particles are conditioned by theapplication of current and curing of the dielectric to provide animproved conductive path through the two electrical contact surfaces,thereby providing an electrical protectant that results in energysavings and with better power transfer and fidelity of electrical (e.g.,audio and visual) signal transfer. It may also be that curing of thedielectric results in a lower dielectric constant, bringing the voltageand current more in phase, resulting in better power transfer withoutthe need for reactive compensation.

After curing, the coating increases electrical conductivity across theelectrical connections, thereby increasing efficiency and minimizingwasted energy that is transformed into heat; lowers resistance acrossthe electrical connections; decreases “micro-arcing” across theconnections; the dielectric carrier, once polymerized via an atmosphericoxygen reaction, protects the contact from future oxidation; the oxidesof silver, to the extent formed, are highly conductive; and cryogenictreatment, when provided, increases the conductivity and efficiency ofthe conductive metals on an atomic level.

The coating may be used in residential power, commercial power,industrial, automotive and any other applications that would benefitfrom energy savings, decreased resistance across the electricalconnection, and life extension of electrical products and appliances.This specifically includes, but is not limited to, circuit panels andbreaker boxes; power transmission devices; power transmissionwire/cabling; lighting; automotive connections; solar arrays; hybrid andconventional vehicles, etc.

It is to be understood that the present invention is not limited to theembodiments described above, but encompasses any and all embodimentswithin the scope of the following claims.

1. An electrical contact enhancing coating, comprising a mixture of: aprecious metal powder component containing particles having a particlesize up to 25 μm; and a vegetable oil-based dielectric carrierpolymerizable with oxygen from the air.
 2. The electrical contactenhancing coating according to claim 1, wherein said precious metalpowder component consists of 100% silver flakes.
 3. The electricalcontact enhancing coating according to claim 1, wherein said preciousmetal powder component consists of 100% silver flakes having an averageparticle size between about 5 μm and 10 μm, actual particle size rangingup to 25 μm.
 4. The electrical contact enhancing coating according toclaim 3, wherein said silver flakes are cryogenically treated silverflakes.
 5. The electrical contact enhancing coating according to claim1, wherein said precious metal powder component consists essentially of,by weight: between about 65% to 85% silver flakes having an averageparticle size between about 5 μm and 10 μm, actual particle size rangingup to 25 μm; and between about 15% to 35% gold flakes having an averageparticle size between about 0.2 μm and 3 μm, actual particle sizeranging up to 15 μm.
 6. The electrical contact enhancing coatingaccording to claim 5, wherein said silver flakes and said gold flakesare cryogenically treated flakes.
 7. The electrical contact enhancingcoating according to claim 1, wherein said precious metal powdercomponent consists essentially of, by weight: about 85% silver flakeshaving an average particle size between about 5 μm and 10 μm; and about15% gold flakes having an average particle size between about 0.2 μm and3 μm, actual particle size ranging up to 15 μm.
 8. The electricalcontact enhancing coating according to claim 1, wherein said preciousmetal powder component consists essentially of, by weight: between about65% to 85% silver flakes having an average particle size between about 5μm and 10 μm, actual particle size ranging up to 25 μm; between about12.5% to 30% gold flakes having an average particle size between about0.2 μm and 3 μm, actual particle size ranging up to 15 μm; and betweenabout 2.5% to 5% palladium spherical particles having an averageparticle size between about 0.5 μm and 1.8 μm, actual particle sizeranging up to 10 μm.
 9. The electrical contact enhancing coatingaccording to claim 8, wherein said silver flakes, said gold flakes, andsaid palladium spherical particles are cryogenically treated powders.10. The electrical contact enhancing coating according to claim 9,wherein said precious metal powder component consists essentially of, byweight: about 85% silver flakes having an average particle size betweenabout 5 μm and 10 μm, actual particle size ranging up to 25 μm; about12.5% gold flakes having an average particle size between about 0.2 μmand 3 μm, actual particle size ranging up to 15 μm; and about 2.5%palladium spherical particles having an average particle size betweenabout 0.5 μm and 1.8 μm, actual particle size ranging up to 10 μm. 11.The electrical contact enhancing coating according to claim 1, whereinsaid dielectric carrier component comprises soybean-based oil.
 12. Theelectrical contact enhancing coating according to claim 1, wherein saiddielectric carrier component further comprises food-grade antioxidantadditives.
 13. A method for protecting an electrical connection toincrease energy efficiency, comprising the steps of: coating a firstelectrical contact with the coating of claim 1; mating the firstelectrical contact with a second electrical contact to form theelectrical connection; and exposing the mated electrical contacts to airin order to polymerize the dielectric carrier component, whereby theelectrical connection is protected against oxidation to increase energyefficiency.
 14. An electrical contact enhancing coating, comprising amixture of: a precious metal powder component containing: silver flakeshaving an average particle size between about 5 μm and 10 μm, actualparticle size ranging up to 25 μm; and gold flakes having an averageparticle size between about 0.2 μm and 3 μm, actual particle sizeranging up to 15 μm; and a vegetable oil-based dielectric carrierpolymerizable with oxygen from the air.
 15. The electrical contactenhancing coating according to claim 14, wherein said precious metalpowder component further comprises palladium spherical particles havingan average particle size between about 0.5 μm and 1.8 μm, actualparticle size ranging up to 10 μm.
 16. The electrical contact enhancingcoating according to claim 15, wherein said precious metal powdercomponent comprises, by weight: between about 65% to 85% silver; betweenabout 12.5% to 30% gold; and between about 2.5% to 5% palladium.
 17. Theelectrical contact enhancing coating according to claim 15, wherein saidprecious metal powder component consists essentially of, by weight:about 85% silver; about 12.5% gold; and about 2.5% palladium.
 18. Theelectrical contact enhancing coating according to claim 14, wherein saidprecious metal powder component comprises, by weight: between about 65%to 85% silver; and between about 15% to 35% gold.
 19. The electricalcontact enhancing coating according to claim 14, wherein said preciousmetal powder component consists essentially of, by weight: about 85%silver; and about 15% gold.
 20. A method for protecting an electricalconnection to increase energy efficiency, comprising the steps of:coating a first electrical contact with the coating of claim 14; matingthe first electrical contact with a second electrical contact to formthe electrical connection; and exposing the mated electrical contacts toair in order to polymerize the dielectric carrier component, whereby theelectrical connection is protected against oxidation to increase energyefficiency.